Spring assembly

ABSTRACT

A box spring assembly including a generally rectangular frame with a first plurality of spring members extending transversely between the sides of the frame and spaced from one another longitudinally of the frame. Each spring member is defined by an integral wire having a straight load section and a fishmouth section at each end thereof. The spring members are disposed in pairs overlapping one another transversely of the assembly. The particular improvement is the disposition of pairs of undulations in the straight sections of each spring member so that the spring members may be positioned or aligned longitudinally of one another by disposing a clip about the straight sections between adjacent pairs of undulations.

United States Patent 91 Surletta 1 Mar. 27, 1973 [54] SPRING ASSEMBLY Primary ExaminerCasmir A. Nunberg [75] Inventor. Zygmunt M. Surletta, Detroit, Mich. Atwmey McGlynn g, Milton & Ethington [73] Assignee: Lear Siegler, lnc., Detroit, Mich. [22] Filed: Jan. 18, 1971 [57] ABSTRACT A box spring assembly including a generally rectangu- [211 Appl' 106972 lar frame with a first plurality of spring members extending transversely between the sides of the frame 52 US. Cl. ..5/247,5/260, 5/255, and Spaced from one another longitudinally of the 5 3 frame. Each spring member is defined by an integral [51] Int. Cl ..A47c 23/02 Wire having a Straight load Section and a fishmouth' [58] Field of Search ..267/1 1 1, -1 12; 5/247, 251, 255, i end f The Spring members are 5 /259 260 261 267 disposed in pairs overlapping one another transversely of the assembly. The particular improvement is the 5 6] References Cited disposition of pairs of undulations in the straight sections of each spring member so that the spring mem- UNITED STATES PATENTS bers may be positioned or aligned longitudinally of one another by disposing a clip about the straight sections between adjacent pairs of undulations 2,993,215 7/1961 Rymland ...5/260 3,286,281 11/ 1966 Slominski ..5/247 10 Claims, 4 Drawing Figures PATENTEUHARZYISB 3 7 2,013

SHEET 10F 2 I NVENTOR.

ATTO RNFY PATEWEDHARZYIQYS ,7 2,013

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ATTORNEY thereof disposed intermediate or between the sides 14 of the frame. In other words, the spring member or frame 22 includes a fishmouth section 26 at each extremity thereof but only one such fishmouth section of each spring member is disposed along or above the extremity or side members 14 of the frame.

There is also included positioning means generally indicated at 45 disposed along the straight sections 24 and coacting with one another between coacting straight sections 24 for positioning the spring members relative to one another, i.e., aligning the spring members.

The spring members are identical to one another and the positioning means includes three pair of undulations 46 in each straight section 24 and a clip 47 disposed about overlapping straight sections 24 between the undulations 46 of each pair, as best illustrated in FIG. 1. Each spring member includes three pair of undulations so that the spring members may be made identically to one another and disposed in backto-backor oppositely disposed relationship with the short lengths 30 or upper legs 30 thereof extending in opposite directions. Thus, one pair of undulations are in the middle of the straight sections whereas the other two pair are evenly spaced in opposite directions from the middle pair. As best illustrated in FIG. 1, two pair of undulations in each straight section have a clip disposed therebetween so as to secure each pair of overlapping spring members together and to align the spring members longitudinally of the assembly. Each clip 47 comprises a piece of metal wrapped about the straight portions between the undulations so that the spring members cannot move longitudinally relative to one another and to establish a total combined length which is consistent from one pair of spring members to the next.

Each assembly also includes a border wire generally indicated at 50 and spaced from the frame 12 and connected to the upper legs 30 of the fishmouth sections 26 disposed adjacent the extremities of the frame 12.

The border wire 50 is generally rectangular and has arcuate corners and includes side and end sections with the end sections extending above and along the second pair of extremities or end 16 of the frame 12.

The assembly also includes a second plurality of spring members generally indicated at 52 having at least one fishmouth section disposed between the end sections of the border wire and the frame above the second pair of extremities or sides 16 of the frame. In other words, the second plurality of spring members 52 are disposed along the ends of the frame. The fishmouth formation of the second plurality of spring members 52 are the same as that shown in FIG. 4. It will be noted that the second spring members have a central straight wire portion which extends along and in parallel relationship to the end portions of the border wire 50 and interconnect the two fishmouth sections.

A plurality of spaced integral straight wires 54 terminate in bent end portions 56 which are connected to the end sections of the border wire by clips. The integral straight wires 54 extend longitudinally of the assembly and are woven through the load bearing straight sections 24 of the transversely extending wire members 22. In other words, the straight wire members 54 extend over the load bearing straight sections of one wire member 22 and then under the straight load bearing section of the next wire member 22 and/or over and under adjacent overlapping pairs, and so on. The straight wire members 54 are clipped by clips 57 to the wire members 22.

As alluded to above, the border wire has arcuate corners and a corner spring, as generally indicated at 60 in FIG. 3, is disposed between the border wire and the frame at each corner. Each corner member 60 is arcuate as viewed in plan in FIG. 1 to conform to the adjacent arcuate corner of the border wire. Each corner spring, as viewed in elevation, includes horizontally extending portions 62 and 64 which are connected to the border frame 50 and to the frame members respectively. A U-shaped portion 66 is connected to the horizontally extending portions by a pair of vertical portions 68. The legs of the U-shaped portions 66 are parallel to the horizontally extending portions 62 and 64 and the base of the U-shaped portion 66 is parallel to the vertical extending portion 68. The upper horizontally extending portion 62 is clipped to the border frame by the clips 69 and the lower horizontally extending portion 64 is stapled to the wood frame members 14 and 16.

The longitudinally extending straight wire members 54 and the various clips comprise means interconnecting the transversely extending spring members 22.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A box spring assembly comprising: a frame having two pair of opposite and generally parallel extremities, a plurality of spring members, each of said spring members including a straight load supporting section, a plurality of said spring members disposed between a first pair of said extremities with the straight sections thereof generally perpendicular to said first pair of extremities, each straight section extending a part of the distance between said first pair of extremities and disposed in juxtaposed overlapping relationship with the straight section of another spring member, positioning means disposed along said straight sections and coacting with one another between overlapping straight sections for positioning said spring members relative to one another, said positioning means in juxtaposed overlapping straight sections being adjacent one another, said spring members being identical to one another with juxtaposed overlapping spring members being disposed opposite to one another so that said positioning means in said juxtaposed overlapping straight sections are oppositely disposed.

2. An assembly as set forth in claim 1 wherein said positioning means includes at least one undulation in each straight section and a clip coacting therewith.

3. An assembly as set forth in claim 1 wherein said positioning means includes at least one pair of undulations in each straight section and a clip disposed about SPRING ASSEMBLY This invention relates to a box spring assembly of the type incorporating spring members defined by formed wire. Formed wire box spring assemblies of the type to which the instant invention pertains are shown in U. S. Pat. Nos. 3,286,281 and 3,487,480. These assemblies utilize a plurality of spring wire elements which have a straight load bearing section with a fishmouth at each end with the fishmouths disposed at the sides of the assembly. As is well known, beds are made with varying different widths such as twin beds, three-quarter size beds, double beds, etc. In order to fabricate box springs in accordance with the teachings of the above-mentioned patents, the spring members which extend transversely across the assembly must be made of various different lengths in order to fabricate box spring assemblies of the various different widths. In order to overcome this problem, a box spring has been developed wherein the spring members extending transversely of the assembly are disposed in overlapping pairs. Such an assembly is disclosed and claimed in copending U. S. application Ser. No. 837,685 filed June 30, 1969, now US. Pat. No; 3,596,299. This assembly has proven very satisfactory, but has presented problems in assembly in that it is difficult to align all of the fishmouths along the sides of the assembly so as to provide straight edges along each side.

Accordingly, it is an object and feature of this invention to provide an improved box spring assembly utilizing individual spring wire members which are uniform in configuration but which may be associated together in different combinations and relationships in overlapping pairs and including positioning means along the straight portions thereof for coacting with one another to position the overlapping spring members relative to one another.

In correlation with the foregoing object and feature, it is another object and feature of this invention to provide a box spring assembly including a frame having two pair of opposite and generally parallel extremities with a plurality of spring members each including a straight load supporting section and disposed between a first pair of the extremities of the frame with the straight sections thereof generally perpendicular to the first pair of extremities and with the spring members disposed in overlapping pairs and including pairs of undulations in the straight portions for coacting with one another by having a clip disposed thereabout so as to position and align the spring members.

Other objects and attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a plan view of a preferred embodiment of the instant invention;

FIG. 2 is a fragmentary cross sectional view taken substantially along line 22 of FIG. 1;

FIG. 3 is a view taken substantially along line 33 of FIG. 1; and

FIG. 4 is a perspective view of the fishmouth section embodied in each spring member utilized in the bed assembly of the instant invention.

Referring now to the drawings wherein like numerals indicate like or corresponding parts throughout the several views, a box spring assembly constructed in accordance with the instant invention is generally shown at 10.

The box spring assembly 10 includes a generally rectangular frame indicated at 12, the frame 12 has two pair of opposite and generally parallel extremities as defined by the side members 14 and the end members 16. The frame also includes the transversely extending members 18 and the longitudinally extending member 20. All of the members of the frame are preferably made of wood as is well known in the art.

The assembly also includes a first plurality of spring members, each of which is indicated at 22. Each of the spring members 22 is defined by an integral wire having a straight load bearing section 24 and a fishmouth section disposed at each end thereof and generally indicated at 26.

Each fishmouth section includes a generally U- shaped portion 28 having upper and lower legs 30 and 32 and extending downwardly from the end of the straight portion 24. The upper leg 30 is shorter than the lower leg 32. Actually the lower leg 32 is a torsion bar and the upper leg 30 is a connecting link connecting the fishmouth with the straight load bearing section 24. The torsion bar 32 is disposed transversely or generally perpendicular to the longitudinal axis of the straight load bearing section 24 as is connecting link or upper leg 30. Thus, each straight load bearing section 24 is disposed between the sides of the fishmouth section as viewed in plan in FIG. 1. The above-mentioned U. S.

Pat. 3,596,299 is directed to the feature of utilizing a plurality of spring members disposed in overlapping relationship to span the distance between the sides or extremities of the box spring assembly and the instant application is directed 'to utilizing positioning means between such overlapping spring members.

Each fishmouth section 26 also includes a V-shaped portion having a torsion bar 34 and upper and lower spacer bars 36 and 38 respectively extending from opposite ends of the torsion bar 34. The spacer bars 36 and 38 define the sides or opposite extremities of each spring member between which the straight load bearing sections 24 are disposed. Preferably the straight load bearing sections 24 are disposed midway between the spacer bars 36 and 38. The upper spacer bar 36 is connected to the lower leg 32 of the U-shaped portion 28. The wire extends from the lower spacer bar 38 and is formed into means comprising the links 40, 42 and 44 which are stapled or otherwise secured to the frame.

A plurality of the spring members 22 are disposed between the first pair of extremities or sides 14 with the straight sections 24 thereof extending a part of the distance between the sides 14 and in juxtaposed overlapping relationship with the straight section of another spring member. The straight sections 24 are therefore generally perpendicular to the first pair of extremities or sides 14. The spring members 22 are spaced from one another in both the direction perpendicular to and the direction parallel to the first pair of extremities or sides 14 so that each straight section 24 extends part of the distance from or between the side extremities or members 14. The spring members 22 are disposed in overlapping pairs so that one fishmouth section 26 of each spring member 22 is disposed adjacent one side or extremity of the frame with the other fishmouth section overlapping straight sections between the undulations of each pair.

4. An assembly as set forth in claim 3 wherein each straight section includes three pair of said undulations with one pair being in the middle of the straight section and the other two pair being evenly spaced in opposite directions from the middle pair.

5. An assembly as set forth in claim 4 wherein two pair of said undulations of each straight section have one of said clips disposed therebetween.

6. An assembly as set forth in claim 3 wherein each of said spring members is defined by an integral wire with a fishmouth section at each end of said straight section thereof, and means interconnecting said spring members.

7. An assembly as set forth in claim 6 wherein each fishmouth section includes a generally U-shaped portion having upper and lower legs and extending downwardly from the end of said straight portion, a V- shaped portion having a torsion bar and upper and lower spacer bars extending from opposite ends thereof, said upper spacer bar being integrally connected to said lower leg, said wire extends from said lower spacer and into means attached to said frame, said upper leg being shorter than said lower leg.

8. An assembly as set forth in claim 7 wherein one of said fishmouth sections of each of said overlapping spring members is disposed adjacent one of said first pair of extremities and the other fishmouth section thereof is disposed intermediate said first pair of extremities, a border wire spaced from said frame and attached to the fishmouth sections disposed adjacent said first pair of extremities, said border wire including end sections extending above and along said second. pair of extremities of said frame, and a second plurality of spring members including at least one of said fishmouth sections disposed between said border wire and said frame along said second pair of extremities of said frame, a pluralityof spaced integral straight wires terminating in bent end portions connected to said end portions of said border wire.

, 9. An assembly as set forth in claim 1 including a border wire spaced from said frame and extending along said extremities thereof, said border wire having arcuate corners, a corner spring disposed between said border wire and said frame at each comer, each comer spring being arcuate as viewed in plan to conform to the adjacent arcuate corner of said border wire, each corner spring as viewed in elevation including horizontally extending portions connected to said frame and said border wire respectively with a U-shaped portion connected to said horizontally extending portions by a pair of vertical portions.

10. A box spring assembly comprising: a generally rectangular frame; a first plurality of spring members extending transversely between the sides of said frame and spaced from one another longitudinally of said frame; each of said spring members defined by an integral wire having a straight load section and a fishmouth section at each end thereof; each of said fishmouth sections including a generally U-shaped portion having upper and lower legs and extending downwardly from the end of said straight portion, said upper leg being shorter than said lower leg, a V-shaped portion havinga torsion bar and upper and lower spacer bars exten mg from opposite ends thereof, said upper spacer bar being connected to said lower leg, said wire extends from said lower spacer bar and is formed into means attached to said frame; a pair of said spring members being juxtaposed in overlapping relationship transversely .of said frame and including at least one pair of undulations disposed adjacent a pair in the adjacent overlapping spring member with clips disposed thereabout between each pair so that a fishmouth section of each spring member is disposed adjacent one side of said frame with the other fishmouth section disposed intermediate said sides of said frame with the fishmouths generally aligned along said sides of said frame, said upper legs of juxtaposed overlapping spring members extending from the respective straight sections in opposite directions from one another so that juxtaposed overlapping spring members and the undulations therein are oppositely disposed; a generally rectangular border wire spaced from said frame and connected to said upper legs of said fishmouth sections disposed adjacent said sides of said frame; a second plurality of spring members including at least one of said fishmouth sections disposed between said frame and said border wire along the ends of said frame; at least one integral straight-wire-extendingdongitudinally of said assembly and terminating in bent end portions connected to said border wire, said straight wire being woven through said iIoad sections of said transversely extending members; said border wire including arcuate comers; and a corner spring disposed between said border wire and said frame of each corner, each corner spring being arcuate as viewed in plan to conform to an arcuate corner of said border wire. 

1. A box spring assembly comprising: a frame having two pair of opposite and generally parallel extremities, a plurality of spring members, each of said spring members including a straight load supporting section, a plurality of said spring members disposed between a first pair of said extremities with the straight sections thereof generally perpendicular to said first pair of extremities, each straight section extending a part of the distance between said first pair of extremities and disposed in juxtaposed overlapping relationship with the straight section of another spring member, positioning means disposed along said straight sections and coacting with one another between overlapping straight sections for positioning said spring members relative to one another, said positioning means in juxtaposed overlapping straight sections being adjacent one another, said spring members being identical to one another with juxtaposed overlapping spring members being disposed opposite to one another so that said positioning means in said juxtaposed overlapping straight sections are oppositely disposed.
 2. An assembly as set forth in claim 1 wherein said positioning means includes at least one undulation in each straight section and a clip coacting therewith.
 3. An assembly as set forth in claim 1 wherein said positioning means includes at least one pair of undulations in each straight section and a clip disposed about overlapping straight sections between the undulations of each pair.
 4. An assembly as set forth in claim 3 wherein each straight section includes three pair of said undulations with one pair being in the middle of the straight section and the other two pair being evenly spaced in opposite directions from the middle pair.
 5. An assembly as set forth in claim 4 wherein two pair of said undulations of each straight section have one of said clips disposed therebetween.
 6. An assembly as set forth in claim 3 wherein each of said spring members is defined by an integral wire with a fishmouth section at each end of said straight section thereof, and means interconnecting said spring members.
 7. An assembly as set forth in claim 6 wherein each fishmouth section includes a generally U-shaped portion having upper and lower legs and extending downwardly from the end of said straight portion, a V-shaped portion having a torsion bar and upper and lower spacer bars extending from opposite ends thereof, said upper spacer bar being integrally connected to said lower leg, said wire extends from said lower spacer and into means attached to said frame, said upper leg being shorter than said lower leg.
 8. An assembly as set forth in claim 7 wherein one of said fishmouth sections of each oF said overlapping spring members is disposed adjacent one of said first pair of extremities and the other fishmouth section thereof is disposed intermediate said first pair of extremities, a border wire spaced from said frame and attached to the fishmouth sections disposed adjacent said first pair of extremities, said border wire including end sections extending above and along said second pair of extremities of said frame, and a second plurality of spring members including at least one of said fishmouth sections disposed between said border wire and said frame along said second pair of extremities of said frame, a plurality of spaced integral straight wires terminating in bent end portions connected to said end portions of said border wire.
 9. An assembly as set forth in claim 1 including a border wire spaced from said frame and extending along said extremities thereof, said border wire having arcuate corners, a corner spring disposed between said border wire and said frame at each corner, each corner spring being arcuate as viewed in plan to conform to the adjacent arcuate corner of said border wire, each corner spring as viewed in elevation including horizontally extending portions connected to said frame and said border wire respectively with a U-shaped portion connected to said horizontally extending portions by a pair of vertical portions.
 10. A box spring assembly comprising: a generally rectangular frame; a first plurality of spring members extending transversely between the sides of said frame and spaced from one another longitudinally of said frame; each of said spring members defined by an integral wire having a straight load section and a fishmouth section at each end thereof; each of said fishmouth sections including a generally U-shaped portion having upper and lower legs and extending downwardly from the end of said straight portion, said upper leg being shorter than said lower leg, a V-shaped portion having a torsion bar and upper and lower spacer bars extending from opposite ends thereof, said upper spacer bar being connected to said lower leg, said wire extends from said lower spacer bar and is formed into means attached to said frame; a pair of said spring members being juxtaposed in overlapping relationship transversely of said frame and including at least one pair of undulations disposed adjacent a pair in the adjacent overlapping spring member with clips disposed thereabout between each pair so that a fishmouth section of each spring member is disposed adjacent one side of said frame with the other fishmouth section disposed intermediate said sides of said frame with the fishmouths generally aligned along said sides of said frame, said upper legs of juxtaposed overlapping spring members extending from the respective straight sections in opposite directions from one another so that juxtaposed overlapping spring members and the undulations therein are oppositely disposed; a generally rectangular border wire spaced from said frame and connected to said upper legs of said fishmouth sections disposed adjacent said sides of said frame; a second plurality of spring members including at least one of said fishmouth sections disposed between said frame and said border wire along the ends of said frame; at least one integral straight wire extending longitudinally of said assembly and terminating in bent end portions connected to said border wire, said straight wire being woven through said load sections of said transversely extending members; said border wire including arcuate corners; and a corner spring disposed between said border wire and said frame of each corner, each corner spring being arcuate as viewed in plan to conform to an arcuate corner of said border wire. 